GENERAL DESIGN RULES

1. Firstly simplify the design that is reduce the number of parts required. This can be done most often by
combining parts, designing one part so that it performs several functions.

2. Design for low-labor-cost operations whenever possible.

3. Avoid generalized statements on drawings that may be difficult for manufacturing personnel to
interpret.

4. Dimensions should be made not from points in space but from specific surfaces or points on the part
itself if at all possible. This facilitates fixture and gauge making and helps avoid tooling, gauge, and
measurement errors.

5. Dimensions should all be from one datum line rather than from a variety of points to simplify tooling
and gauging and avoid overlap of tolerances. It is also preferable to base as many dimensions as possible
from the same datum line as seen in Fig. 1

Fig 1

6. Designers should strive for minimum weight consistent with strength and stiffness requirements.
Along with a reduction in materials costs, there usually will be a reduction in labor and tooling costs
when less material is used.

7. Whenever possible, design to use general-purpose tooling rather than special tooling (dies, form
cutters, etc.).
8. Avoid sharp corners; use generous fillets and radii. Generously rounded corners provide a number of
advantages. There is less stress concentration on the part and on the tool; both will last longer. Material
will flow better during manufacture.

9. Design a part so that as many manufacturing operations as possible can be performed without
repositioning it reducing handling and the number of operations.

10. Whenever possible, cast, molded, or powder-metal parts should be designed so that stepped parting
lines are avoided. These increase mold and pattern complexity and cost.

11. With all casting and molding processes, it is a good idea to design work pieces so that wall
thicknesses are as uniform as possible. With high-shrinkage materials (e.g., plastics and aluminum), the
need is greater.

12. Space holes in machined, cast, molded, or stamped parts so that they can be made in one operation
without tooling weakness. Most manufacturing processes for producing multiple holes have limitations
of minimum hole spacing as seen in Fig. 2

Fig 2